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Pressure Testing
Pressure testing is used to determine the integrity of pressure equipment and piping systems. It is based on g the ability y of a piping p p g system y to withstand a determining hydrostatic pressure that equals or exceeds the design pressure (test pressure depends on the type of test). The tests criteria are pressure history and leak detection. A test is conducted by isolating and pressurizing the vessel/piping, and then measuring the change in pressure over a specified time. At the same time, visual inspection f l for leaks k is i conducted d t d. The test pressure shall, unless otherwise specified, be in accordance with applicable code (e.g., ASME BPVC, ASME B31.3, ASME B31.4, API 1110, etc.).
Just prior to test start-up, pre-test calculations should be performed to detect the presence of entrained air.
Test Media
For hydrostatic testing the test medium shall in general be fresh water, water except that other suitable liquid may be used if:
The piping or inline equipment would be adversely affected by water. If the liquid is flammable, its flash point shall be at least 49 49C C and consideration shall be given to the environment. The liquid is approved by the Owner
Test Media
The chloride ion content of the water used for pressure testing stainless steel lines shall be less than 100 ppm and the line shall be properly drained soon after testing. The pH of the water shall be between 6.5 and 7.5. For pneumatic testing, the test media shall be oil free, dry air or any inert gas. The extent of pneumatic testing shall be approved approved. Specific safety precautions and requirements generally apply.
Pneumatic Testing
Pneumatic testing is normally used in cases where water contamination of the service fluid is not tolerated or when water of suitable quality is not available. Typically, Owner approval is required before pneumatic testing is to be performed. Additionally, because of the potential energy of the compressed air (gas) in the system under pneumatic testing testing, special safety precautions and procedures have to be implemented.
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{ 1 (P1/Ph)
-1 1
Vh = The volume of the vessel. Ph = The absolute pressure of the vessel. Pl = The absolute pressure to which the vessel would drop if it burst, generally one atmosphere (14.696 psi or 101,300 Pascal). A Pascal is a Newton per square meter. = The adiabatic exponent or ratio of specific heats, Cp/Cv. (= 1.67 for monatomic gases; 1.4 for diatomic gases; 1.3 polyatomic gases)
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Potential Energy
Stored Volumes of Ideal Gas at 20 C PRESSURE, psig 10 100 1000 10000 TNT EQUIV., lbs. per ft3 0.001 0.02 1.42 6.53
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Test Procedure
Test Procedure: The pressure source shall be attended constantly during the test. test Should it be necessary for the operator to leave the pressure source, he should first relieve the pressure in the test loop. A preliminary check shall be made by pressurizing the test loop to not more than 25 psig. At each increment of 25 psig, psig the pressure shall be held steady for one minute before processing to a higher pressure
Test Procedure
The following typical procedure shall be used:
1. Cl 1 Close all ll valves l in i the th line li and/or d/ blank bl k off ff all ll flanges. fl 2. Open the valve supplying the test fluid to the pipe system slowly until the pressure gauge indicates 25 psig. 3. Close the valve supplying pressure. 4. Observe the pressure gauge. If the pressure holds steady for one minute, proceed to Step 5. 5. Open the valve supplying pressure.
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Test Procedure
6. Increase the test pressure in the line by 25 psi. 7. Close the valve supplying pressure. 8. Repeat Steps 4, 5, 6 and 7 until the Test Pressure is achieved. 9. Hold the Test Pressure for a period of time sufficient to permit a thorough inspection of all joints for leakage, but not less than 10 minutes. The pneumatic pressure test results are acceptable when there is no evidence of l k leakage or seepage and d no decrease d in i pressure shown h on the test gauge during the test. 10. Relieve the pressure in the test loop.
Test Procedure
Repair any leaks found in the test loop. After repairs, i retest t t the th test t t loop l per Steps St 1 thru th 10 above at the Test Pressure. Retesting also requires a stepwise pressure increased in 25 psig increments.
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Test Record
Test Record: The test shall be witnessed by the designated Engineer (and other individuals as required by regulations). Records of the pressure test shall be maintained by the per company policies as identified on the Pressure Test Record Form. Records should include the test date, identification of the h pipeline i li tested d and d the h type of f pressure test used d with reference to the appropriate project and maintenance files.
110 100 90 80
Pneumatic test pressure for pressure vessels Maximum Allowable working Pressure, MAWP Maximum relief device setting Retest pressure for all vessels and systems Maximum operating pressure, MOP*
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Hydrostatic Testing - 1
Hydrostatic testing is used to conduct strength tests on:
new pipes while in the manufacturing process, as well as at the completion of pipeline installation in the field prior to being placed in service.
Hydrostatic testing is also used, at times, for integrity assurance after a pipeline is in operation. Hydrostatic tests are generally the preferred integrity assessment method when the pipeline is not capable of being internally inspected or if defects are suspected that may not be detectable by internal inspection smart pigs.
Hydrostatic Testing - 2
Hydrostatic test establishes the pressure carrying capacity of a pipeline and may identify defects that could affect integrity during operation. Testing is done to a pressure that is greater than the normal operating pressure of the pipeline. This provides a margin of safety. The Th test stresses the h pipeline i li to a predetermined d i d percentage of its specified minimum yield strength (SMYS). Typically pressures range from 93% to 100% of SMYS, and the test is generally held for eight hours.
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Hydrostatic Testing - 3
If stress corrosion cracking (SCC) is suspected, the test pressure may be increased to 100% to 105% of SMYS or higher for 30 minutes to an hour. Axial flaws such as stress corrosion cracking, longitudinal seam cracking, selective seam corrosion, long narrow axial (channel) corrosion and axial gouges are difficult to detect with Magnetic Flux Leakage (MFL) pigs and are better detected with a hydrostatic test.
Hydrostatic Testing - 4
Hydrostatic testing requires the ability to acquire large quantities of test water, which in some areas may be difficult. Once used, the test water may contain trace quantities of petroleum products, which may require treatment of the water prior to discharging or disposal. Hydrostatic H d i testing i requires i the h pipeline i li to be b out of f service for a period of time thus potentially curtailing the availability of gasoline, jet fuel, diesel fuel, crude oil, and/or home heating oil at the delivery point.
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Leak Testing
Leak testing may be used to find leaks in a newly constructed or newly modified piping system system, or in an established system where an apparent loss of integrity has been experienced. If they exist, leaks typically occur at joints (or from through wall defects). Typically, Typically the pressure does not exceed the maximum operating pressure.
Leak Testing
Leak testing does not verify pressure rating or potential long long-term term performance. performance The system design and the pressure ratings of the installed components are the sole determinants of system pressure rating and long-term performance. Safety is of paramount importance. Leak tests can apply high stress to untried joints and parts in the system Failure can occur by leaking or by system. catastrophic rupture. In some cases, leakage may immediately precede catastrophic rupture.
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Some US Regulations
192.507 Test requirements for pipelines to operate at a hoop stress less than 30 percent of SMYS and at or above 100 psi. (689 kPa). Except for service lines and plastic pipelines, each segment of a pipeline that is to be operated at a hoop stress less than 30 percent of SMYS and at or above 100 p psi ( (689 kPa) ) must be tested in accordance with the following: (a) The pipeline operator must use a test procedure that will ensure discovery of all potentially hazardous leaks in the segment being tested
Some US Regulations
(b) If If, during the test test, the segment is to be stressed to 20 % or more of SMYS and natural gas, inert gas, or air is the test medium:
(1) A leak test must be made at a pressure between 100 psi. (689 kPa) gage and the pressure required to produce a hoop stress of 20 % of SMYS; or (2) The line must be walked to check for leaks while the hoop stress is held at approximately 20 % of SMYS.
(c) The pressure must be maintained at or above the test pressure for at least 1 hour.
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Service Tests
Service tests are usually applied to non-critical service such as utility and other low pressure nonnon hazardous services. Illustrative examples: (1) Non-flammable and non-toxic fluids (2) Design pressures less than 150 psig (3) Operating temperatures range: -20 to 366o F. The criteria for application of service tests should be clearly established in the owner specifications.
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Pneumatic Tests
Pneumatic testing is normally used in cases where water contamination of the service fluid is not tolerated or when water of suitable quality is not available. Typically, Owner approval is required before pneumatic testing is to be performed. Additionally, because of the potential energy of the h compressed d air i (gas) ( ) in i the h system under d pneumatic testing, special safety precautions and procedures have to be implemented. Test pressure for pressure vessels = 110% X DP
Leak Detection
Technology is available to detect leaks from gas pipelines. pipelines One approach involves the use of sensitive sensors on board low- flying surveillance airplanes that fly along he pipe route. Another approach entails the use of methods based on analysis of time series of pressure and/or flow i b l imbalance because b these h present some well ll known k reaction to leaks. A software-based system is typically used for such application.
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